Drywall tape applicator

ABSTRACT

An apparatus such as a hand-held drywall tape applicator is provided for applying a fluid-activated tape onto a wallboard or ceiling joint. The apparatus includes a housing defined by a left housing section and a right housing section. The housing is configured to removably mount a roll of tape at the rear end. The apparatus includes a base, a handle disposed between and coupled with the base and the rear end of the housing, a nozzle assembly attached to or defined by the front end of the housing, and a basin detachably coupled with the housing and configured to hold a fluid. The apparatus further includes a plurality of rollers, which include a first roller disposed inside the basin. The plurality of rollers are configured to feed and transport a portion of tape from the roll into the fluid of the basin and then out of the nozzle assembly.

PRIORITY CLAIM AND CROSS-REFERENCE

This application claims the benefit of U.S. Provisional Application No. 62/525,434, filed Jun. 27, 2017, and U.S. Provisional Application No. 62/548,705, filed Aug. 22, 2017, each of which is expressly incorporated by reference herein in its entirety.

BACKGROUND

This invention relates to a step in the construction of interior walls of a building, typically a home, apartment, office building or other types of buildings. After the wall of the building is constructed using wooden studs or members, it is common to cover the wooden studs with dry wall, also called wallboard or sheet rock. The dry wall is fastened in place by nailing or using fasteners to attach it to the wooden studs. Once the dry wall is in place, joints are formed where two pieces of wallboard abut each other. The joints formed between adjoining drywall or wallboard panels are usually covered with a lamination of joint compound and fibrous drywall tape to hide the cracks defined by and between the abutting panels. These joints, or gaps, in the dry wall need to be filled in before the wall can be painted or wallpapered for aesthetic reasons, or else visible lines of discontinuities appear in a finished wall. Filling in these joints has required a four-step process.

The first step in filling the joints is applying a layer of thick paste, called mastic or joint compound. Once the joint compound is applied using a trowel or pressurized hand-operated tool, and while the joint compound is still wet, the dry wall tape is applied over the wet joint compound and pushed into the wall joint. Joint compound and tape may be applied manually or by using a trowel or a pressurized hand-operated tape and compound dispenser to lay down a thin layer of compound and tape over each joint. When using such a tool, the joint compound may be applied to at least the side of the tape that faces the wallboard panel. A relatively narrow and thin coating of joint compound subsequently is applied over the initial lamination of joint compound and tape using a trowel or a pressurized joint compound applicator. Otherwise, taping is done by hand, which is extremely time-consuming and requires many man-hours of labor. Taping is the second step but it is often combined with the first step through the use of the compound and tape dispenser tool. Once the initial layer of joint compound and tape is applied, it is smoothed over with a tool, such as a roller, and allowed to dry overnight. Allowing the first application of joint compound to dry thoroughly has been found to be advantageous because the compound shrinks as it dries. Allowing the first layer of compound and tape to dry thoroughly permits completion of the shrinking process so that the resulting crevice can be filled in completely.

The third operation is to apply a thicker second layer of compound over the tape. The compound layer covers the exposed or outer edges of the drywall tape and sandwiches the tape between the first layer of joint compound and the newly applied layer. This compound layer acts to blend the tape into the wall by covering the edges of the tape and any remaining groove in the joint. This second layer of joint compound is allowed to thoroughly dry for 24 to 48 hours, and then a third and thinner layer of joint compound is then applied over the second layer. Sanding is then required to smooth over the joint.

The fourth step in finishing walls is widely practiced. A third, layer of joint compound is applied over the second layer after the second layer has dried thoroughly and been sanded. This third layer is feathered into the walls, resulting in an even finish, which makes the abutment of the two wallboards virtually invisible when painted or covered with wallpaper. Because the second layer of compound is the thickest, it is common to allow the second layer to dry for at least one day, sometimes two days, before the third layer is applied.

These four steps originally were performed by hand, and were all time-consuming and labor intensive, taking more than a couple of days. Particular skill is needed to apply the tape and compound over both an inside corner join and an outside corner. A need developed for methods and apparatuses that would reduce the time and effort required to form a finished wallboard joint having a wallboard tape sandwiched between two layers of joint compound and to have quicker and easier methods of applying drywall tape to inside corner joints and outside corners. Over several decades, a need developed for a method and an apparatus for applying simultaneously joint compound to both sides of the wallboard tape as the tape is pressed against a joint between abutted wallboard panels. A further need existed for such a method and an apparatus that applies tape and compound to corner joints in a single application requiring no further application of compound to complete the taped joint. This led to numerous developments in the field to reduce the time and effort required to finish the walls. Despite these efforts, little progress has been made over the years.

A popular applicator system used commercially was known as a “Bazooka.” Variations of the tool were sold from a number of manufacturers, but never functioned properly or efficiently. These tools used a hollow, telescoping, cylindrical handle with an actuator and a piston. The handle was filled with joint compound, and the operator pushed on the actuator section of the handle to push the compound to the head of the tool where the taping mechanism was affixed. The taping mechanism received the compound and applied it to the wall-side of the tape as the tape was being applied to the joint. The drawback of the “Bazooka” style applicator was that the process was messy, resulted in an uneven thickness in the layer of drywall compound applied to the surface, and involved complicated equipment and multiple components that were susceptible to breaking down, which often happened. This method of application required the extra step of washing, cleaning and pressing down of the uneven edges of the tape where extra joint compound had seeped from the applicator. These applicators were difficult to use because the operator must apply even pressure on the device when manually applying the tape, and to do so with heavy equipment was laborious and tiring.

Generally, while drywall tape applicators applied tape and compound at a faster rate than when tape is applied manually, many of the early drywall tape applicator tools had annoying drawbacks that resulted in poor acceptance of these devices by the building trades. A particularly annoying drawback was the bothersome need to wipe down the tape and compound once it was applied to a wall joint. The applicators were not able to adequately smooth or iron out the tape and compound so as to form a continuous, even surface during the same stroke in which they are dispensed. This condition required the additional step of a follow-up or cleanup procedure wherein excess compound was removed with a putty knife, and irregularities, bumps and bubbles formed beneath the tape had to be flattened. The application process for taping inside corners and outside corners became even more complicated by use of these applicator tools, if not impossible.

Another drawback of many mechanized tape and compound applicators were their cumbersome and complicated structure. An applicator loaded with compound could weigh up to 40 pounds and extend over a length of 4 to 5 feet. The use of these devices was tiring to the operators, making smooth wall finishing work and corner work difficult to achieve with such an awkward, heavy device.

Still other drawbacks of tape and compound applicators included a tendency to frequently break down because they had numerous moving parts that were highly prone to failure. Another drawback was the applicator's inability to adequately produce a clean, tight corner or angle joint. These earlier applicators could not apply tape and compound at the 90-degree angle typically formed at corners and at wall-ceiling joints.

Over time additional drawbacks to existing drywall tape applicators became apparent. For instance, when applying tape such as a paper, mesh or adhesive-backed tape, it was necessary to take the tape from a roll, and apply it to a joint that may be as short as a few inches or as long as 30 or 40 feet—for instance if a long joint is formed extending up a wall, across a ceiling and down another wall. The application of tape using devices with joint compound was messy and awkward over long distances. Furthermore, these devices did not enable an operator to apply uniform pressure to the tape so that it was uniformly embedded in the joint compound, without air bubbles in the case of plain paper, and so that it was not wrinkled or straying excessively from the joint line. An applicator was necessary for an operator to easily manipulate for both ceiling and wall work. The early mechanized compound and drywall tape applicators could not fulfill these needs.

Another area in which problems existed was in both vertical and horizontal corners. For instance, often sheets of drywall did not meet at their edges in corners, and thus the preformed edge groove was uneven. In such a case, it was even more important that the tape lie flat against the surfaces of the drywall sheets. Secondly, when manually applying drywall tape to such corners, the operator must fold the tape longitudinally in a “V” shape so that it could be accurately placed in the corner; however, the operators had no free hands if they used such heavy tools and resorted to manual application. These applicator tools, which failed commercially, were ineffective in applying drywall tape to a corner, as formed between abutting wall sheets, or as formed between abutting wall and ceiling sheets or on outside corners between separate walls.

Numerous dispensers have been developed for applying a substance to a strip of material prior to application of the strip to another surface, including drywall joint compound dispensers that applied compound to the tape before application of the tape on the seams of wallboards. Examples of these prior art dispensers are shown in U.S. Pat. Nos. 3,496,909; 3,513,809; 3,381,661; 3,292,575; 4,067,294; 4,090,914 and 4,159,695.

Drywall taping tools have been available for a long time in an attempt to fulfill the needs noted above. For instance, U.S. Pat. No. 3,116,195 relates to an applicator that applied tape coated on one side with compound to a joint. The applicator received compound from a supply hopper by means of an internal combustion engine powering a positive displacement pump. Despite carbon monoxide gas dangers associated with operating a gasoline engine indoors, the positive displacement pump relied upon a relief valve to divert extra compound back into the supply hopper via a bypass line if excess pressures developed. Because positive displacement pumps had the capacity to generate tremendous pressures, it was unwise to rely on a mechanical valve, which was in constant contact with the thick cement-like paste, to open in order to avoid casualties.

U.S. Pat. No. 3,880,701 discloses an applicator with an elongated form for dispensing tape from a tape roll and applying joint compound from a reservoir to the tape as it is dispensed. A cutting knife is actuated by a slide member forward of the tape roll for severing the tape at desired lengths. A braking mechanism stops the tape from being dispensed and is actuated by the same means that actuates the cutting knife, but the brake applies a normal braking force to the tape thereby frustrating the use of adhesive-backed tape. The applicator is equipped with a short handle that limits the user's range of motion, requiring that an operator be assisted with stilts, a ladder and/or scaffolding to apply tape to elevated seams on a wall or ceiling.

U.S. Pat. No. 3,960,643 also provides a dual utility of tape and compound application to wallboard seams. The disclosed device is also limited by a relatively short handle, and the compound application makes the device cumbersome. A pull-handle actuates a cutting blade, but no brake is applied to assist in the cutting process.

U.S. Pat. No. 4,080,240 relates to a similar taping tool with a pneumatic pump having two tanks containing compound and floating pistons resting on the surface of the compound. A compressor supplies high-pressure air to the top of the tanks, above the pistons, placing downward pressure on the pistons to push the joint compound through a supply line to the applicator device. When the supply tanks are empty, the pistons are removed by using high pressure from the compressor to the bottom of the tanks. Valve alignment is crucial to operation in either mode, and it is dangerous to use high-pressure air to deliver a potential projectile to an operator.

U.S. Pat. No. 4,086,121 teaches a self-contained drywall taper that has a hollow elongated body for holding mastic and supports a roll of tape with tape feeding means to deliver the tape to tape-applying wheels which, in turn, apply it to cover the wall board joint. A piston is slidably mounted in the hollow body and is automatically moved by a mechanism actuated by the wheels, as they are moved over the wallboard surface, to force a layer of mastic onto the tape just prior to it being applied to the surface. Tape feeding and cutting means are actuated by a single sleeve which is moved forwardly on the hollow body to initially feed the tape into engagement with the tape-applying wheels and is moved backwardly to actual the tape-cutting mechanism. A tape-operating disc can be swung into position when the tape to be applied is to fit into an inner corner of a room, and it is desirable to force a median crease lengthwise along the tape as the mastic and tape are applied.

U.S. Pat. No. 4,196,028 discloses a cumbersome device that provides for the application of tape and compound to wall seams, including corner seams. A sliding control member in front of the tape roll actuates a cutting blade.

U.S. Pat. No. 4,208,239 discloses a hand-operated dry wall taping tool that includes a tubular main body portion, which is held by the operator. The tool is supplied with dry wall tape cement from a pressurized source. A supply roll of dry wall tape is carried from the main body of the applicator, fed through the applicator head onto the wall joint to be taped. In the applicator head, a pair of tape drive wheels engages the tape and presses it against the wall for taping a wall seam. As the drive wheels pull the tape through the applicator head, drywall cement is applied by the applicator head to the side of the tape that is to engage the wall. In one embodiment, a spring biased swivel roller presses the cement-laden tape into the wall as the tape is applied to the seam. In an alternative embodiment, a flexible resilient wiper blade carried from the head presses the cement-laden tape into the wall and feathers the cement onto the dry wall along both side edges of the tape.

U.S. Pat. No. 4,406,730 teaches a hand-held, portable dry wall tape dispenser to be used with adhesive mesh tape on which the adhesive is pre-applied. The taping tool comprised an open frame between in which a pair of feed rollers thread the tape from a supply roll inside of the frame of the tool, and a wide, flat pressure roller is used to press the tape onto flat wall surfaces. The tool also has a second V-shaped or convex roller that is extendable and could be fitted within the frame and fixed in a forward position by a pin. The convex roller permits application of the pre-adhesive tape in corners and at wall and ceiling joints. The tape also has a corner roller that could be pivotally mounted for movement into a position along the path of the tape for application along corners and between adjoining drywall sections.

U.S. Pat. No. 4,452,663 discloses a device for applying tape and compound to wallboard seams. The applicator is equipped with a trigger-actuated brake that applies a normal braking force to the dispensed tape. No integrated cutting mechanism is included.

U.S. Pat. No. 4,555,298 teaches a device for dispensing and applying adhesive drywall tape. The devised frame consists of a pair of spaced parallel arms connected to an elongated handle parallel thereto. An applicator roller is positioned near the open ends of the arms to raw tape from a tape roll and presses the tape, during use, into final position. The device also has a blade position near the open end of the arms above the applicator roller. The blade is movable so, when withdrawn, it is in a parallel position to the arms where it does not obstruct the dispensing of tape from the device. The blade is then extended beyond the frame and applicator roll to permit cutting the tape transversely.

U.S. Pat. No. 4,652,331 discloses a tape and adhesive applicator for dry wall tape that has an adhesive dispensing nozzle and an applicator roll mounted adjacent the outlet of the nozzle. The nozzle has an opening adjacent to its inlet for receiving a tape for passage through the nozzle from the opening to the nozzle outlet, where adhesive is then applied to one side of the tape. The applicator works much like a caulking gun (a “Bazooka”), with a spring-based adjustable gate member to control the application of adhesive and to act as a pressure relief valve if the pressure in the caulking gun becomes too great. The device has a plunger-activated cutter to cut the tape to proper length.

U.S. Pat. No. 4,689,107 addresses many of the drawbacks of drywall tape applicators by disclosing a lightweight applicator that applies a continuous and even coat of wallboard compound to a strip of wallboard tape, while simultaneously wiping down the tape so as to obviate the need for a subsequent wipe-up and cleanup procedure. The device is an applicator that simultaneously dispenses wallboard tape and compound from a pressurized reservoir that acts as a fluid capacitor to ensure an even application of compound to the tape. The applicator is attached to a pressurized tank of compound through a hose that delivers compound to the device. The applicator device has a dispensing nozzle comprised of a casing having an internal passage formed therein for guiding the tape through the applicator. The casing is housed in a rectangular-shaped block for applying tape and compound over flat surfaces. A storage chamber within the nozzle casing serves as a surge tank or fluid capacitor for the pressurized wallboard compound. This chamber has a width slightly less than the width of the tape, which prevents the compound from spreading out toward the edges of the tape when applied to the wallboard under the compressive force of the casing. The chamber does not apply compound over the entire width of the tape, whereas conventional applicators applied compound over the entire tape surface. The applicator disclosed in this invention avoids the waste of compound and the need to clean up or wipe the tape after it is applied to the wallboard.

U.S. Pat. No. 4,689,107 discloses the problem of irregularities in the tape on the wall, which is due to the poorly controlled compound feed rates of existing tools, such as spring-loaded feed mechanism (i.e., “Bazookas”) that would fail to provide a smooth, continuous supply of compound to the applicator nozzle.

U.S. Pat. No. 4,707,202 addresses the drawback of applying drywall tape to corner joints. The invention consists of a device with a cast head and a handle attached to one end, with the head being adapted to releasably and rotatably mount a roll of adhesive tape. A roller assembly at the other end of the head includes frame members pivotally mounted to the head, with two rollers rotatably mounted between the frame members. For flat joints, the rollers are both cylindrical, and are at least as wide as the adhesive tape. For corner joints, the first applicator roll is about half as wide as the tape, and the second applicator roller has an inverted V-shaped profile for pushing the tape into the corner. As the device is moved along the corner, tape fed from the roll is initially formed to have a transversely concave shape by the first applicator roller, contacting only the edges thereof, and formed into a right angle by the second applicator roller. The roller assembly pivots relative to the head as the device is moved along the corner to keep the rollers in contact with the wall sections defining the corner. A cutting mechanism is provided to cut the applied tape from the tape roll.

U.S. Pat. No. 4,750,968 applies to a device for applying tape to an elongated exterior corner, with the head being adapted to releasably and rotatably hold a roll of tape. A roller assembly at the other end of the head includes a triangular frame pivotally attachable to the head, where guide and applicator rollers are rotatably mounted. The guide rollers are cylindrical and spaced apart on one shaft. The applicator rollers are frustoconical and are mounted on another shaft to define a V-shaped zone. During use, the tape taken from the roll is preformed about the corner by the guide rollers and is stretched against the corner by the applicator rollers. The outer surface of each roller is softer than its inner core to facilitate stretching the tape and conforming the tape into a corner.

U.S. Pat. No. 4,775,442 discloses an apparatus for dispensing drywall tape and wallboard compound and comprises a nozzle that applies the compound through a series of opposed feed channels. Each feed channel applies a bead of compound to one side of the tape as the tape passes through the nozzle in longitudinally folded condition. Upon exiting the nozzle, the tape is unfolded and the compound is uniformly extruded beneath the tape. Venting grooves extend from the feed channels to the nozzle exit to prevent clogging of the feed channels by the tape.

U.S. Pat. No. 4,828,647 discloses an apparatus for applying tape and mastic to joints between prefabricated wall sections such as gypsum board comprising a tubular housing, which holds a supply of mastic, a main drive roller mounted at the forward end of the housing, which rotates by friction as it is moved along a wall, and a tape drive roller means operated by the main drive roller, which feeds the tape forward.

U.S. Pat. No. 4,913,766 describes a tape applicator having a tape-cutting blade actuated by a push-rod assembly.

U.S. Pat. No. 5,013,389 teaches an apparatus for taping wall joints comprising a taping head, slidingly contractible with a wall, for simultaneously applying a first layer of joint compound between pieces of wall board, embedding a drywall tape in the first layer of compound and over-coating the embedded drywall tape with at least one additional layer of joint compound. The apparatus further comprises a handle connected to the tape head that is manually graspable by the operator, having a fluid conduit for passing joint compound to the taping hand. A tape supplied is mounted on the handle, and the operator wears a backpack containing a supply of joint compound and for producing a pressurized stream of the joint compound. A flexible hose connects the backpack conduit for joint compound to the taping apparatus. U.S. Pat. No. 5,279,684 is a continuation of U.S. Pat. No. 5,013,3989. U.S. Pat. No. 5,279,700 is a continuation-in-part that discloses the same complex system of applying joint compound and tape using a pressurized tank and hosing system.

U.S. Pat. No. 5,114,527 discloses a drywall tape applicator where the tape moves through a chamber containing joint compound and out through a dispensing opening for application to a wall joint. The dispensing opening is formed in part by an adjustably mounted plate that is positioned and controlled by a rotatable knob. The plate is held within close tolerance in a slideway so that the dispensing opening defines an accurately controlled slot of uniform width. The bottom wall of the housing has a convex configuration so that when the tape is in close proximity to the bottom wall, the tape is applied with a proper amount of joint compound.

U.S. Pat. No. 5,800,668 discloses an apparatus for taping work that eliminates kneeling, stooping, or bending by the operator. The apparatus is comprised of a carriage body having wheels and a push handle for moving the apparatus. The push handle is of a height that allows a user to tape a surface while standing in an upright position. The carriage body mounts a tape dispenser coupled to a tape-registering device on its front surface. A roll of tape is mounted in the dispenser, and tape is first fed manually to the tape-registering device, which registers the tape upon a work surface. Upon firm registration, the apparatus is wheeled forward, and the tape is automatically unrolled and applied to the work surface. The tape dispenser and tape-registering device can be unfastened as a unit and selectively positioned in a different geometric plane, for taping a new work surface. For instance, the user can tape a ground surface using the push apparatus and then adjust the tape dispense and tape registering device to tape a wall surface.

U.S. Pat. No. 5,814,184 teaches a tape applicator that applies adhesive-backed drywall tape along both flat and corner joints. The applicator has a common tape dispenser to which a flat joint header and corner joint header can be removably attached. The dispenser has a tape guide located near a tape outlet as well as a tape break. The flat joint header has cylindrical application roller with a resilient surface that allows the roller to follow the contour of the wall while maintaining proper pressure distribution to completely and securely press the tape against the wall. The corner header includes a creaser wheel that creases the tape into a corner and a guide roller that guides the tape from the dispenser to the creaser wheel. A corner roller on the applicator head is used to effectively wipe down creased tape over a corner joint. Both the flat joint and corner headers include tape cutters to selectively cut the tape from the dispenser. The applicator is designed for adhesive-backed tapes, including reinforced drywall tape, fire tape and mesh tape.

U.S. Pat. No. 6,294,034 discloses a drywall texture and tape-dispensing device that has a hand-held dispenser with a mud chamber. The dispenser tapers toward an exit end with two parallel slots for dispensing a thin layer of dry wall mud onto a dry wall surface along with the drywall tape. A semi-rigid, flexible strap is affixed to the dispenser and extends past its back end. The strap has an armband that secures to the arm of the user. The device also has a pair of tape guide loops that are loosely joined to the strap to allow flexibility and twisting. A blade is affixed to the dispenser for the purpose of smoothing drywall mud on a work surface. A mud line is provided to receive mud for delivery to the mud chamber. A tape dispenser is supported by the user typically on the user's belt. The tape dispenser is positioned to feed tape through the guide loops and out through the tape-dispensing slot on the exit end of the hand-held dispenser for application to a surface. The user applies the mud and tape simultaneously to a wall surface. The blade is used to smooth the mud and tape combination onto the surface.

U.S. Pat. No. 6,299,686 discloses a drywall taping and texture system for pumping drywall mastic from a container filled with drywall mastic to a work surface. The apparatus includes a pump housing, an air compressor, a tool for applying the drywall mastic to the work surface, material and control lines, an inflatable bladder, an air release mechanism, and an airway. The pump housing is immersed in the container filled with the drywall mastic, and the air compressor is connected to the pump housing. The material and control lines are connected between the pump housing and the tool, so that there is material and airflow communication. The bladder is mounted within the pump housing between upper and lower valves for controlling the flow of the drywall mastic. The airway connects the air compressor, the control line, the bladder, and the air release mechanism, so that there is airflow communication there between. When the air release mechanism closes, the bladder inflates so that drywall mastic in the pump housing is pumped through the upper valve, the material line, and the tool to the work surface. When the air release mechanism opens, the bladder deflates so that a partial vacuum is created within the pump and drywall mastic material in the container is pumped through the lower valve into the pump housing.

U.S. Pat. No. 6,419,773 discloses a drywall tape and compound applicator whereby a strip of drywall tape is simultaneously coated with drywall compound on its opposite front and rear surfaces as the tape is applied to a corner joint formed between a pair of abutting wallboards, such as drywall panels. A tape guide provided on a drywall taping head guides a folded strip of drywall tape over a first reservoir of drywall compound. The compound flows through the first reservoir and against the V-shaped front surface of the tape. The compound continues to flow over and around the front surface of the tape and over the rear surface and laterally into a pair of second reservoirs.

U.S. Pat. No. 6,450,723 teaches a tool for applying joint compound to a corner joint formed at the intersection of two drywall panels during new construction. The tool has a generally flat top surface with leading edges that converge toward an apex. A housing on the top surface is in spaced relationship from the leading edges and includes a chamber for the receipt of joint compound from a pressurized source. The housing has discharge ports that are forwardly directed. In use, the head is positioned in the corner and tilted in the direction so that the discharge ports face the corner. The head is tilted to an extent necessary to cause the leading edges to engage the adjacent walls forming the corner. In this position, the head can be drawn along the corner as the joint compound is discharged into the corner vicinity and is troweled by the leading edges.

U.S. Pat. No. 6,513,562 discloses a unitary nozzle for use in a taping apparatus. The unit features a cradle section next to a tube receiving section and a flange for receiving a mastic tube for sealing purposes. A mastic is extruded and contained along a path extending along one side of the tape and between a front and rear end of the nozzle.

U.S. Pat. No. 6,668,897 relates to a tape and joint compound dispenser that is formed by a housing defining an interior chamber for joint compound and joint tape. A valved port in the housing opens into the chamber for supplying joint compound. A tape lifter in the chamber enables the user to lift the tape in the chamber to facilitate supplying the joint compound to the chamber through the port and below the tape. This invention is embodied as a tape gun for applying joint tape and joint compound to drywall joints. The tool is formed by the housing having opposed side walls spaced apart a width that is determined by the width of the drywall tape being applied, and peripheral top, bottom and end walls. The housing contains a chamber for holding the joint compound for application to the tape. The housing further has an entrance slot in one end wall opening into the chamber for receiving the tape for apply joint compound, and an exit slot for supplying the tape with joint compound on to the drywall joint. A tape lifter is swingably mounted in the housing chamber and extends into the chamber between the tape entrance slot and the tape exit slot. When the tape gun is in use, the lifter is positioned adjacent the lower chamber wall with the tape positioned between the lifter and the upper chamber wall. For actuating the tape lifter, a handle is swingably mounted on the outside of the housing and is operatively connected to the tape lifter for swinging the lifter to lift the tape and position it against the upper wall of the chamber. The handle retracts the lifter to position the same adjacent the bottom wall of the chamber. The housing also has a valved port in one wall through which joint compound is introduced in the chamber below the lifted tape. In this manner, joint compound can be supplied to the chamber through the port and below the tape for subsequent application to the tape as the tape passes through the slots for application to drywall joints.

U.S. Pat. No. 6,712,238 discloses a drywall tape and texture system for pumping fluid material from a container to a work surface and includes a pump housing, a compressed air supply, a plurality of air release mechanisms, and an inflatable bladder mounted within the pump housing and held between upper and lower valves for controlling the flow of fluid material. The pump housing may be fully or partially immersed into a container filled with fluid material. An automatic pneumatic pressure relief valve automatically cycles open and closed whenever a control line is held closed by an operator. When the normally closed automatic air release mechanism is closed, the control line also may be closed by the operator, causing the bladder to inflate and pump fluid out of the pump housing. When the control line to the atmosphere is opened, the bladder deflates and a partial vacuum is created, refilling the pump housing through a lower valve. The system has interchangeable tools for applying tape and adding texture to compound applied to the drywall board panels.

US Pat. App. No. 2001/0003563 discloses an apparatus for the application of drywall compound onto an already taped drywall joint. The applicator uses an electrically powered, positive displacement pump, which supplies a continuous flow of compound from a hopper to the applicator head via a fluid path. Remote controls on the handle of the applicator allow the operator to turn the pump on or off and also to select the optimal pump speed. The hopper is large enough so that an operator can apply compound to a number of joints before having to stop and refill the apparatus with compound.

US Pat. App. No. 2003/0029542 discloses a tape and joint compound dispenser for wall surfaces that automatically matches the delivery of the compound to the feed of the tape. The system has a compartment or tank that contains compound. A pump supplies compound from the tank through a flexible conduit to an applicator, which dispenses tape and compound. A sensor measures the rate of speed of the tape as it is being dispensed and provides a signal to a controller. The controller varies the flow rate by varying the speed of the motor that drives a pump. An auger is rotated within the tank for pre-feeding compound to the pump as well as for mixing the compound. As the tape feeds from the applicator onto the wallboard, the tape sensor senses the rate of the tape feed and signals the controller to cause the pressure source to flow compound through a conduit and out the applicator. The controller continuously monitors the tape speed signal and varies the rate of compound flowing from the applicator.

US Pat. App. No. 2005/0034415 comprises an apparatus and method for applying and embedding drywall tape in joint compound along a drywall joint. The apparatus includes an applicator for guiding the tape along the joint and provided with a handle structure and a blade portion having slots to guide the tape. Tape is guided through a first slot at the rear end of a handle structure, and the tape is guided through a second slot in an extended blade portion of said handle structure at the opposite end of the handle structure to one end. The tape is guided through a third slot in said extended portion remote from the handle structure. The guided tape is pressed onto the joint compound along the drywall joint with sufficient force to spread the joint compound simultaneously moving the extended portion along the drywall joint, thereby continually embedding the tape in the drywall compound along the drywall joint and spreading the joint compound contacted by the tape.

US Pat. No. 2005/0051278 discloses an apparatus adapted for applying a drywall tape to a wall seam. The frame of the apparatus has an opening through which tape is dispensed from a roll, and a roller is carried by the frame adjacent the opening for pressing material dispensed through the opening from the rotatably-supported roll against the wall surface. A brake also is supported by the frame for applying a braking force to the roll of material, thereby preventing material from being dispensed through the opening from the roll as desired. An actuator is connected to the elongated handle opposite the frame for remotely actuating the brake. In one embodiment, the apparatus includes a cutting member. The apparatus has an elongated handle so that an operator can dispense tape above his head.

US Pat. App. No. 2007/0107337 discloses an apparatus for applying tape and joint compound to a drywall that has a pan member having a predetermined shape and size and formed of a material suitable for holding drywall joint compound. A holder means that is engageable with the pan member is designed for holding a roll of drywall tape. There is a slot disposed on each end of the pan for permitting tape to enter one end of the pan member and exit a second end of the pan member, with the tape exiting the second end of the pan as it is covered on substantially an upper side with such joint compound. A holder means is designed for holding a roll of drywall tape and as tape is unwound, it enters the first end of the pan member and exits the second end after a coating of joint compound covers the upper side of the tape.

U.S. Pat. No. 7,537,037 teaches a stackable drywall tape and joint compound dispenser that includes a tape holder and a reservoir for storing drywall compound. When the dispenser is placed on another dispenser of substantially the same configuration, at least one of the respective tape holders and reservoirs nest with one another so as to enable one to store multiple dispensers in a compact space. This enables the dispenser to be easily cleaned. The dispenser can be configured so that when the dispenser is placed on another dispenser of substantially the same configuration, at least one of the respective tape holders and/or reservoirs of each dispenser nest with one another. The reservoir can include an input port for receiving drywall tape, and an output port for dispensing drywall tape coated with joint compound. At least one of the input port and the output port can be formed to inhibit leakage of the joint compound from the reservoir. The dispenser can be a multi-piece or single-piece unit and can include a cutting edge, such as a sharp or serrated edge for cutting the drywall tape. Further, the dispenser can include a selectively retractable platform coupled to the dispenser via a hinge or it can be detachable from the dispenser.

U.S. Pat. No. 7,568,513 teaches an elongated, rectangular container with sides and a base that encloses a cavity. The sides are connected to the base and extend upwardly from the base. The end wall has a first slot and a substantially opposing second slot. Each of the first and second slots is sized to permit a first end of a tape located on a roll to be slid through it. A tape holder lies outside of the cavity of the container. The tape placed on the holder is pulled manually through the cavity holding joint compound, and as it is pulled through the cavity, joint compound is thinly applied to one side of the tape. As this is done, the joint compound begins to adhere to the tape, conditioning the tape for adhesion to the wall. A lip up of stainless steel on each side of the base, on both sides of the tape, keeps the tape in alignments as it passes through the cavity containing joint compound. The tape holder swings up or down by the means of an arm action for easy reloading. As the roll of tape sits on a base, gravity and friction keep the roll from moving around as the tape is pulled through. The second slot that the tape passes through is gauged to permit the proper thickness of the joint compound to be applied to the tape. At the dispensing end, there is a means of severing the tape at a selected length.

U.S. Pat. No. 7,621,309 discloses a drywall taper for applying drywall compound and tape to a wallboard joint. The drywall taper has an applicator head mounted on one end of a drywall compound storage device having a movable plunger with a drywall compound flow path extending from an opposite end of the storage device to an outlet on the applicator head. A pressurized air arrangement is provided for pushing the plunger and delivering drywall compound through the drywall compound flow path. An actuating arrangement is slidably disposed upon the storage body and is engaged with a tape advancing mechanism, a tape severing device and a creaser wheel assembly for separately controlling tape advancement, tape severing and creaser wheel movement. In another embodiment, the plunger is eliminated so that a substantially continuous flow of pressurized drywall compound is provided through an unobstructed delivery tube to the applicable head.

U.S. Pat. No. 7,766,065 discloses a device for applying drywall tape and grouting compound to a drywall. The invention simplifies the process of applying drywall tape and an appropriate amount of grouting compound to a joint. The applicator device is placed on a standard size tub of drywall grouting compound so that the compound adheres to the drywall tape as it is drawn through the applicator device by the operator applying tape to a joint to be filled. The tape is drawn through a series of pins that apply a coating of drywall compound so that the tape, upon exiting the applicator, retains a coating of drywall joint compound. The applicator has a further means of cutting the tape upon exit to the desired length,

U.S. Pat. No. 7,823,617 teaches a spring powered sliding drywall taping tool with an auto cutter. The dispenser has an elongated handle and a tape or trim dispensing head. The head can contain a blade that is coupled to a power mechanism such as a spring, hydraulic or electric energy source, where the blade can be placed into a cocked position by a cocking mechanism and then triggered by a pull on a remote trigger located on the handle. After the device is cocked, the user can dispense the tape or trim to a desired length and then cut it exactly by a simple trigger pull. The tape is applied to joint compound and adheres to the wall.

U.S. Pat. No. 7,926,442 teaches a tape applicator device that has a container with a periphery and a base, which encloses a cavity. The device has a periphery first slot and a substantially opposing second slot. Each slot is sized to permit the first end of a tape located on a roll to be slid through the cavity. The cavity is filled with joint mud or compound. A tape holder may be connected to the container so that the tape holder lies outside the cavity of the container. When the tape is unwound, it is manually unwound and pulled through the mud box. Joint compound is thinly applied to one side of the tape and begins to adhere to the tape, conditioning the tape for adhesion to a wall.

US Pat. App. No. 2012/001085 discloses an apparatus and method for a tape dispenser that includes a first housing and tape rotational hub, a tape aperture feeding into a tape channel, and a cutter pivotally attached to the first housing. The cutter extends through the housing through a cutter aperture in a cutter state, and the cutter retracts from the cutter aperture being urged into a retracted state. A roller is attached to the first housing and positioned adjacent to the non-adhesive side of the tape. The roller routes the strip of tape around the cutter to feed the strip of tape into the tape aperture and tape channel. The tape channel is positioned adjacent to a surface, and the apparatus is pulled to lay the strip of tape upon the wall surface. The tape is cut in selective lengths by the cutter.

U.S. Pat. No. 8,286,681 relates to a fluid-activated drywall tape applicator that includes a roll of fluid-activated drywall tape, a container, a lid and at least two slits. In operation, the roll of tape is affixed to the applicator, and a lead edge of the tape is fed through the first slit. The fluid in the container saturates the tape, and the tape leaves the container through the second slit. After leaving the container via the second slit, the tape's adhesive properties are activated and the user may apply the tape to a working surface. The applicator is intended to be used with a self-adhesive tape, which, when run through a container of fluid, has adhesive properties that are activated. The applicator has successive rollers to ensure complete saturation of the tape and then squeeze out excess fluid prior to application to a wall joint. The applicator is meant to clip to the belt of an operator. Some of the problems that need to be addressed by this applicator include leakage of fluid onto the tape so that the roll of tape locks up; the tape may require further moistening by the use of a wetted sponged or immersing the tape in a vessel of water or a further dispensing device that employs a wetted sponge. In order to ensure adherence of the drywall tape to a joint, preferably a sponge, plaster knife, or hand brushing of the applied tape length across the joint is required to ensure proper contact, bonding wellness, and a smooth drying result.

U.S. Pat. No. 8,517,077 relates to an automatic taper for drywall with an easily removable cover plate which may allow a user to obtain easy access to the interior nozzle of the taper. The user may gain access to the interior of the nozzle by flipping a rotating securing bar upward and then removing the removable cover plate.

U.S. Pat. No. 8,783,322 discloses a taping tool having a swivel joint and a creaser wheel for creasing the tape that is used for taping gaps, seams and joints between wallboard pieces and other construction materials. The taping tool has a first portion that receives a flow of mastic used to adhere the tape to the construction materials, and a second portion for receiving the flow of mastic and for dispensing tape and mastic. The first and second portions have fluid communication pathways allowing mastic to flow through. The “mastic” comprises drywall compound, glue, caulk, resin, epoxy or similar substances. The tape is formed from paper, fiberglass or other material, may be woven or nonwoven, and may or may not have an adhesive backing. The swivel joint on the tool enables the tool's first portion to rotate relative to the second portion through an angle of 360 degrees about the tool's longitudinal axis while mastic is still flowing through the taping tool. The tool allows the dispensing of tape and mastic at any angle relative to the first portion of the taping tool so that the user need not contort his or her body in order to apply the tape in difficult or hard-to-reach locations.

SUMMARY OF THE INVENTION

The present disclosure provides a simple, lightweight, easy-to-use, hand-held apparatus or applicator tool for applying drywall tape (e.g., paper based drywall tape) to drywall joints where the edges of wallboard abut each other. The applicator is used to apply drywall tape that has an adhesive on one side that is activated when it comes into contact with a fluid such as water. In some embodiments, the applicator applies water-based adhesive backed tape after the tape passes through an attached water basin, and the tape is dispensed and simultaneously applied to the wallboard joints. The applicator has advantages over prior applicators because it uses water, not messy joint compounds, to activate the adhesive on the tape and adhere the tape to the wallboard joint. Further, the invention makes applying water-based adhesive tape faster than applying tape manually or with applicators that require saturation of the tape by a joint compound. The applicator can be used with pre-adhesive paper tapes that may be pre-creased or not creased, that have a plurality of holes over the entire surface of the tape, or that have a series of holes down the center of the tape or any water-activated adhesive tape with a continuous surface.

The applicator avoids cumbersome parts, like pumps, air compressors, pressurized systems, large tanks of joint compound, and other mechanical components that frequently break down and are difficult and tiring to use. Those complicated applicator systems have cumbersome and complicated structures. An applicator tool loaded with joint compound could weigh up to 40 pounds and extend over a length of 4 to 5 feet. The use of those devices are tiring to the operators, making smooth wall finishing work difficult to achieve with such an awkward, heavy device. In some embodiments, the present hand-held invention is a tool that has an approximate length (L in FIG. 1) of only 12 inches, a width (W in FIG. 2) of approximately 3.25 inches, and a height of approximately 8.5 inches (H in FIG. 3), and is easily held and used by an operator using only one right or left hand. No large tanks of joint compound and complicated hoses, pressurized or compressed air systems are necessary.

The present applicator or apparatus provided in the present disclosure further improves upon other hand-held drywall tape and compound application systems using joint compound to apply tapes because it eliminates the messiness of applying drywall tape using joint compound. Joint compounds often clog applicators, or result in an uneven layer of joint compound, air bubbles, bumps and irregularities in the tape and sloppy joint compound extending beyond the edges of the tape, necessitating the step of wiping or cleaning up at the edges of the tape on the wall. Moreover, the systems applying joint compound and tapes are messy and awkward when applying tape over long lengths, such as 30 or 40 feet. Use of these tools usually necessities that the operator take an additional step of wiping or cleaning the applied drywall tape and compound with a trowel or other tool, and the heaviness of these prior systems are a drawback because they are exhausting for the operator to use. In contrast, the present lightweight applicator invention is easily held in one hand and is made from lightweight materials, obviating the use of complicated hosing, pumping, compressed or pressurized air systems.

Moreover, the present invention improves the application process by cutting the time the operator spends in applying the tape to wall and ceiling joints. Because of the efficiency of the method using the tool provided in the present disclosure, an operator can apply at least twice the length of drywall tape using the applicator compared with the time of manual application.

The present invention also improves upon prior tape application systems by combining the first and second steps in the process of finishing wall and ceiling joints, minimizing labor, facilitating easy application of drywall tape in wall and ceiling joints, and eliminating the need for 24- to 36-hour drying time necessitated by systems that simultaneously apply drywall tape using joint compound or mastic. Once drywall tape is applied using this applicator over the first application of joint compound to wall or ceiling joints, the drying time necessary before applying the second layer of joint compound can be as short as 15 minutes to a half hour. Moreover, the present invention applies tape evenly, eliminating bubbles, bumps and irregularities in the tape after application.

The present invention solves the drawbacks of prior drywall taping tools and provides a lightweight, easy to use, hand-held apparatus used to apply drywall tape to wallboard and ceiling joints when finishing walls during construction. The preferred embodiment of the applicator tool comprises a right housing section, a left housing section, a liquid container (or basin), left and right nozzle mechanism or a single nozzle mechanism, mating interlocking features, roll holders and one or more rollers. The base, handle grip and nozzle mechanism are formed by joining the left housing and the right housings sections using up to four screws with the housing allowing up to four (or more) rollers of the same or different sizes. Another embodiment may include less than four rollers, or no rollers, and an individual pre-assembled nozzle piece that is attached to the dispensing end of the right and left enjoined housings. The right and left housings have round roll holders that are sized to hold rolls of drywall tape.

The tool is designed for use with water-based or water-actuated adhesive-backed drywall tape to be applied to wall and ceiling joints before an initial application of joint compound. The leading edge of the tape is pulled and fed downward into the water basin using a roll wetting guide piece that is formed by the right and left housings and that extends into the water basin. The tape is fed around a roller inside the removable water basin at the bottom of the roll wetting guide piece where contact with water actuates the adhesive on the underside of the tape. The tape then passes upward out of the water basin through another roller inside the housing above the water basin and in the middle of the enjoined housing. In some embodiments, the water basin contains approximately 4 to 6 ounces of water or an amount sufficient to apply at least 100 feet of drywall tape. The basin easily snaps into place using mating interlocking features extending on the left and right sides of the assembled housing that slide into a slot in the left and right housing sections.

After exiting the water basin, the leading edge of the tape is then pulled through a pair of adjacent rollers substantially forming a nip in the nozzle end of the apparatus. The nip rollers remove any excess water from the tape and prevent the tape from curling or folding in upon itself. The operator lightly presses the nozzle end of the tool against the wall surface to easily apply tape into the wall or ceiling joint with one easy swing of the arm. The rotatable nozzle mechanism (or nozzle assembly) allows the tape to be applied either vertically or horizontally in select lengths. The operator easily twists the tool downward or sideways so as to cut the tape to desired lengths using the cutting mechanism, which is a serrated bar affixed to the top of the joined nozzle mechanism. The nozzle mechanism has built-in notches that interact with notches in the housing to stop the nozzle assembly in the correct position for application of tape either horizontally or vertically. The nozzle assembly also has a guide notch that is useful for the operator applying tape directionally. The taping tool also provides easy application in corner joints by clipping to an operator's belt. The operator manually presses the tape that is dispensed easily and swiftly from the tool into the corner joint before an initial application of joint compound. The applicator facilitates and speeds up the application of drywall tape to wallboards and significantly shortens the application time and finishing time of walls during construction.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevational view of an apparatus in accordance with the invention for applying drywall tape over flat joints between sections of wallboard and in corner joints of wall and ceiling joints.

FIG. 2 is a top view of a fully assembled apparatus in accordance with the invention for applying drywall tape over flat sections of wallboard and in corner joints of wall and ceiling joints.

FIG. 3 is a front elevational view of the apparatus showing the nozzle section whereby the drywall tape dispensed from the apparatus in accordance with the invention for applying drywall tape.

FIG. 4 is a side elevational view of the one half of the housing of the apparatus in accordance with the invention, illustrating the housing with a roll of drywall wall tape mounted thereon, placement of the rolls, roll wetting feature, water basin, nozzle section, and the method of threading the tape through the housing and other features of the apparatus.

FIG. 5 is a front and top view of the base, housing and nozzle of the apparatus shown in an unassembled split view of each of the above features of the apparatus.

FIG. 6 illustrates the shape and features of the rollers in the apparatus in accordance with the invention for applying drywall tape over flat sections of wallboard and in corner joints of wall and ceiling joints.

FIG. 7 illustrate the features of the nozzle portion of the apparatus that is separate from the front housing portion of the apparatus and that is inserted into the front housing portion when fully assembled.

FIG. 8 illustrates the fully assembled apparatus showing specific features of the apparatus in accordance with the invention for applying drywall tape over flat or corner wall or ceiling joints.

FIG. 9 is a back view of a clip-on corner mechanism showing the clip that is used to attach the corner mechanism to the nozzle end of the apparatus for applying drywall tape to inside corner joint and outside corner joints.

FIG. 10 is a side elevational view of the fully assembled apparatus showing the corner mechanism attached to the nozzle mechanism for applying drywall to inside and outside corner joints.

FIG. 11 is a front view of the open dispensing end of a fully assembled apparatus in accordance with the invention for applying drywall tape in corner joints of wall and ceiling joints with the corner mechanism mounted on the nozzle end of the apparatus.

FIG. 12 is a front elevational view of the apparatus showing the nozzle section to which the corner mechanism is attached whereby the drywall tape dispensed from the apparatus.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates the side profile of an exemplary assembled apparatus or drywall tape applicator 100, which, in accordance with the invention, is used for applying drywall tape to wall and ceiling joints in wallboard as part of the construction of walls. Such a joint may be formed by two pieces of drywall or ceiling board and includes a joint on one wall plane or a corner joint. The drywall tape has one side coated with adhesive, which can be activated with a fluid such as water. The adhesive is water-based adhesive in some embodiments.

The drywall tape applicator 100 is made from an injection molded plastic polymeric material in some embodiments. The features and components of the applicator tool are formed by joining a right housing section 2 and a left housing section 4 by means of screws, bolts, mating tabs, adhesive, or other known fastening methods. In the preferred embodiment, the left and right housing sections 2, 4, when assembled, comprise a base 10, a handle 30, a housing 40, and a nozzle assembly 60, and the sections are joined using screws. The components of the drywall tape applicator 100 include a right and left housing section 2, 4, which, when assembled, forms a base 10 that, is an elongated, rectangular flat surface. One screw 20 in the front end of the base 10 is used to join the left and right housings 2, 4. A second screw 24 is used to join the left and right housing sections at the base end of a handle (or handle grip) 30, which extends above the base 10 and is positioned at approximately a 75-85 degree from the horizontal base 10.

The back end 32 of the handle grip 30 is slightly curved and the front end 34 of the handle grip 30 defines concaved grooves 36 that are suitable for fitting the grip of an operator's right or left hand. Both sides of the handle grip 30 are covered partially with an imprinted oblong section 35 on the surface thereof having a plurality of small circular imprinted dots 37 that assist in securing the operator's hold on the handle grip 30. The oblong imprinted section 35 of the surface of each side of the handle grip 30 covers a substantial length of the handle grip 30 sufficient to facilitate the operator holding and gripping the handle grip 30. Another screw (a third screw) 28 at the top of the handle grip 30 is used to joint together the left and right housings 2, 4.

The apparatus 100 also includes a basin or container 70, which is detachably coupled with the housing 40 and is configured to hold fluid such as water. The left housing section 2 and the right housing section 4, when assembled, defines and forms at least the housing 40. The housing having a front end 42 and a rear end 44. In some embodiments, the handle 30 is disposed between and coupled with the base 10 and the rear end 44 of the housing 40. In some embodiments, the left housing section 2 and the right housing section 4 made of plastics, when assembled, defines and forms the base 10, a handle 30, a nozzle assembly 60. The nozzle assembly 60 may be separately attached to or defined by the front end 42 of the housing 40. The housing 40 may be open from its top in some embodiments. In some embodiments, the nozzle assembly 60 is rotatable with respect to a longitudinal axis 50 of the housing 40 so that the tape can be applied horizontally or vertically. The nozzle assembly 60 comprises a cutting bar 80 configured to cut a portion of tape transported out of the nozzle assembly.

FIG. 1 further illustrates the housing 40 that is formed by a left housing section 2 and a right housing section 4 (illustrated in FIG. 2), both of similar shape, form, dimensions, and pre-molded features that form the single housing 40 as assembled. The left section 2 and the right section 4 of the housing 40 are attached by another screw 27 at the bottom of housing 40, approximately halfway between the front nozzle assembly 60 and the back end 44 of the enjoined housing 40, and above the front end of water basin 70. Two screws 27 hold together the nozzle assembly 60 at the front end (or the dispensing end) 42 of the apparatus 100.

In some embodiments, the left housing section 2 and the right housing section 2 defines and provides a roll holder (or holders) 11 in the housing 40 configured to removably mount a roll of tape 19 (FIG. 4). In some embodiments, the back end 44 of the housing 40 when assembled forms a rounded shape large enough to hold a roll of drywall tape on circular roll holders 11, which are raised circular shapes on the right and left housing sections 2, 4 in the interior of the back end 44 of the housing 40 when assembled. The circular roll holders 11 are for the purpose of fitting the core of a roll of drywall tape 19 for dispensing at the back end 42 of the housing 40. The circular roll holders 11 have a diameter suitable for holding the core of a roll of drywall tape 19. In a preferred embodiment, the circular roll holders 11 are approximately two (2) inches in diameter, or sized suitably to hold a core of a roll of drywall tape 19 that is slightly larger in diameter than the circular roll holders 11, so that the roll of tape 19 is held in place and is easily and smoothly dispensed through the apparatus 100.

The assembled housing 40 illustrated in FIG. 1 is made of a polymeric plastic material. The sides of each of the right and left sections of the housing 40 comprise a finely grooved surface over the plurality of the housing 40. The top of the housing 40 is open so that a roll of tape 19 can easily be placed onto the circular roll holders 11, and threaded through the apparatus 100. On both sides of the outer surface of the housing 40 slightly in front of the circular roll holders 11 and behind the point at which the water basin 70 snaps into the housing 40 is a rectangular belt tab 12 with circular edges. The belt tab 12 is attached to the outer surface of the right and left sections of the housing 40. The top edge of the belt tab 12 extends away from the side of the housing 40 on the two side edges and the bottom edge to form a flexible clip of substantial strength for attaching the drywall tape applicator 100 to an operator's belt. This enables the operator to have both hands free while the operator is using the apparatus to apply drywall tape manually in corner wall or ceiling joints. In a preferred embodiment, the rectangular belt tab 12 is between 0.8 to 1.2 inches wide and 1.2 to 1.35 inches wide, large enough and of sufficient weight so as to be flexible and to support the weight of the apparatus when the water basin 15 is attached and filled.

On the front end 42 of the housing 40 near the nozzle assembly 60 includes five narrow, indented slit features 13 of the same length. The slit features 13 extend down the side of one section of the housing 40, wrap around the bottom of the front end of the housing 40, and extend up the other side of the opposite section of the housing 40. The five narrow slit features 13 facilitate rotating and re-orientating the nozzle assembly 60 from a horizontal position to a vertical position, or from a vertical to a horizontal position. Across the horizontal top of the nozzle assembly 60 is a ridged or serrated bar affixed thereto constituting a cutting bar 80 for severing tape at select lengths by the operator rotating the tool directionally downward or horizontally.

In the middle of both the left and right sections 2, 4 of the housing 40 depicted in FIG. 1 is a circular hole 14 for the purpose of clipping the water basin 70 into place in the bottom of the housing 40. The circular hole 14 is on both sides of the housing 40 in the same position in the left and right sections 2, 4, respectively, of the housing 40. A feature of the water basin 70 on both sides is a rectangular slot mating feature 19 with rounded upper edges and a raised circle. The slot mating feature 19 extends above the sides of the water basin 70, and enables the water basin 70 to be clipped into the open circular holes 14 in the left and right sections 2, 4 of the housing 40. The slot mating feature 19 is sized and configured so as to snap the water basin 70 tightly and flush onto the bottom of the housing 40 so there is no leakage or spillage of water from the water basin 70. In a preferred embodiment the water basin 70 holds sufficient water or other fluid to apply between a 50-foot or 100-foot role of drywall tape and is made of a high wear-resistance standard clear ABS material. The water basin 70 is shaped with a flat bottom and four planar sides that form a container that is wider at the top of the water basin 70 than at the flat bottom surface of the water basin 70.

FIG. 2 illustrates a top view of the open top of the housing 40 of the apparatus 100 for applying drywall tape over flat sections of wallboard and in corner joints of wall and ceiling joints. FIG. 2 shows that the apparatus 100, in a preferred embodiment is approximately 3.0-3.25 inches wide (“W” in FIG. 2). The line 52 down the center of the apparatus 100 represents the line at which each the left and right sections 2, 4 of the housing 40 meet and become screwed together to form the housing 40. The circular roll holders 11 for holding a roll of drywall tape 19 are at the back end 44 of the housing 40 above the point at which the left and right sections 2, 4, of the housing 40 are attached at the top of the handle grip 30. The back end of the base 10, shaped as a rectangle with rounded corners, is visible beneath the handle grip 30. The open circular holes 14 in the slot feature 19 are located in the approximate center of the housing 40 lengthwise and used to snap the water basin 70 in place on the bottom of the housing 40. On the nozzle assembly 60 is a horizontal ridged and serrated cut bar 80 on top of the nozzle feature 60.

FIG. 3 illustrates an elevational view of the front, or nozzle feature, end 42 of the housing. The nozzle assembly 60 comprises a left and right section 2, 4 that are screwed together to form a rotatable dispensing feature that is rounded on the bottom 64 and rectangular at the top 62, with a horizontal ridged and serrated cut bar 80. The nozzle assembly 60 holds two rollers 93 (FIG. 4) at a nip point, through which the drywall tape exits the apparatus 100. The bottom of the nozzle assembly 60 is a half circle in shape preferably with a diameter of approximately 2.5 to 3.0 inches. The top 62 of the nozzle assembly 60 is rectangular and preferably approximately 2.5 to 3.0 inches in width. On the top 62 of the nozzle feature 60 is a ridged, serrated cut bar 80 that is an integral part of the injection-molded nozzle assembly 60 for severing the tape from the dispenser.

The apparatus 100 further includes a plurality of rollers 90 in some embodiments. The plurality of rollers 90 include a first roller 95 disposed inside the basin 70. The plurality of rollers 90 are configured to feed and transport or dispense a portion of tape 21 from the roll 19 into the fluid of the basin 70 and then out of the nozzle assembly 60. The tape 21 is coated with adhesive on one side, which can be activated with the fluid such as water. The plurality of rollers 90 include a second roller 93 a and a third roller 93 b disposed parallel to each other to provide a nip at one end of the nozzle assembly 60 and configured to transport the portion of tape out of the nozzle assembly 60. The second and third rollers 93 may also comprise a plurality of ribs 97 (FIG. 6) for removing excessive fluid. The plurality of rollers 90 may also include a fourth roller 98 disposed inside the housing 40 and between the first roller 95 and the pair of the second and third rollers 93. In some embodiments, the apparatus 100 further comprises at least one guide 48 disposed on the nozzle assembly 60 and configured to guide the tape out in a straight line.

FIG. 4 illustrates a split open view of the one section of the housing 40 of the drywall tool with a roll of drywall wall tape 19 mounted on the circular roller holders 11 at the top of the housing 40. Only the right housing section 4 is used. The tape 21 is fed through slanted roll guide features 43, which are part of the housing 40. The tape 21 is fed down and around one side of the elongated roll wetting feature 44, which extends from the bottom of the housing 40. The tape 21 is fed around a first roller 95 at the bottom of the roll wetting feature 44, then up the other side of the roll wetting feature 44 into a roller 98 (referred as a fourth roller), which guides the water-saturated tape toward the nozzle assembly 60. A second slanted guide feature 46 is disposed above the roller 98 in some embodiments. The roller 98 turns the tape 21 so that the underside of the tape 21 coated with the liquid-activated adhesive is on the underside of the tape as it exits the nozzle assembly 60. From the roller 98, the tape 21 is pulled and fed to two rollers 93 (referred as the second and third rollers), which are placed sufficiently in proximity to each other to form a nip. Such a nip serves to eliminate excess water from the tape and prevent the tape from folding or curling in on itself as the tape exits the nozzle assembly 60 and is applied to the wallboard, ceiling or corner joints. The rollers 93 are held in place by the left and right sections of the nozzle assembly 60 when screwed together.

FIG. 5 illustrates the complete nozzle assembly 60 showing the left and right sections 2, 4 of the housing 40 unassembled, the left and right sections of the nozzle assembly 60 itself, the rollers 93, 95, 98, and the base 10 of the apparatus 100. The water basin 70 is shown to have two rectangular tabs 72 with rounded edges extending up from the left and right sides of the water basin 70, each with a round circle 74 that abuts from the surface of the rectangular tabs 72. The round circles 74 are used as mating features to snap the water basin 70 into the slot features 19 on the left and right sides 2, 4 of the housing 40 so as to hold the water basin 70 flush to the bottom of the housing 40.

FIG. 6 illustrates the rollers 93, 95, 98 that are the same size and design in some embodiments. Rollers 93, 95, 98 may have different design and dimension in some other embodiments. The rollers 93, 95, 98 are preferably around ½ inch in diameter and approximately 2.0-2.5 inches in length. The rollers 93, 95, 98 have approximately 10-12 rib features 97 that are useful for guiding the tape through the apparatus 100 and preventing the tape 21 from curling in on itself as it is pulled through the apparatus 100. In the preferred embodiment, the rollers 93, 95, 98 are made of a wear-resistant polymer.

FIG. 7 depicts the open dispensing end 62 of the nozzle assembly 60 at the dispensing end 42 of the housing 40, which has three notches 64 that are stopping points at which the rotatable nozzle feature 66 is kept in position when re-orientated for either horizontal or vertical use by a left- or right-handed operator. The rotatable nozzle feature 66 includes a guide feature 48 that extends out from the rounded bottom half of the nozzle assembly 60 to assist the operator in guiding the tape in a straight line as it is dispensed through the rollers 93. The rotatable nozzle feature 66 is fitted into the open dispensing end 62 of the housing 40. The rotatable nozzle feature 66 can be rotated approximately thirty (30) degrees from a horizontal position at the middle notch 68 a to the upper notch 68 b in the open dispensing end 62. It can be also rotated downward approximately thirty (30) degrees from a horizontal position at the middle notch 68 a to the lower notch 68 b in the open dispensing end 62 of the housing 40.

The apparatus 100 may further comprise at least one belt tab 12, for example, two belt tabs, attached to an exterior surface of the housing 40. The at least one belt tab 12 has a clip sized and configured to removably couple the apparatus 100 onto an operator's belt. FIG. 8 illustrates the fully assembled apparatus 100 and depicts additional useful and innovative features used by the operator for dispensing drywall tape. The tab 12 is used to clip the apparatus 100 to the operator's belt so that the operator can use the apparatus 100 hands-free, dispensing tape 21 with the tool in one hand while guiding the drywall tape 21 into corner wall or ceiling joints with the other hand. The guide feature 48 is used by the operator in guiding application of the tape 21 in a straight line. The cutting bar 80 is used by the operator to tear the dispensed drywall tape at the desired length. In some embodiments, the cutting bar 80 is formed from the left and right housing sections 2, 4 and is a part of the nozzle assembly 60.

In some embodiments, the apparatus 100 further comprises a corner mechanism 104 removably coupled with the nozzle assembly 60 and is configured to apply a portion of tape 21 onto a corner joint. The corner mechanism 104 includes a triangular base and two sidewalls 109 providing a right angle 107, and is configured to fold the portion of tape 21 when the portion of tape 21 is dispensed out of the nozzle assembly 60. In some embodiments, the corner mechanism 104 comprises an elongated clip structure 106 having an upside-down U-shape cross-section removably coupled onto the cutting bar 80. FIG. 9 is a back view of a corner mechanism 104 that can be attached to the rotatable nozzle feature 66 using a clip 106 that is mounted on top of the serrated, ridged cut bar 80 on top of the nozzle assembly 60. The corner mechanism 104 is a removable piece of the apparatus 100 that is used to apply drywall tape to inside and outside corner joints. The corner mechanism 104 has a clip feature 106 that is formed in a horizontal, upside down U-shape with right corners, of the appropriate size to fit over the serrated ridged cut bar 80 and stay in place while drywall tape 21 is dispensed from the open dispensing end 62 of the nozzle assembly 60. The bottom 105 of the corner mechanism 104 forms a triangle which is used to fold the drywall tape 21 simultaneously as it is dispensed from the open dispensing end 62.

FIG. 10 is a side elevational view of the fully assembled drywall tape apparatus 100. As illustrated in FIG. 10, the corner mechanism 104, at the front portion, has two sidewalls 109 that meet to form a right angle 107 such that the angle juts forward from the apparatus above the open dispensing end 62 of the nozzle assembly 104 and is aligned with the center of the nozzle assembly 60. The corner mechanism 104 has rounded edges 112 and a rounded base 114 that extends to a triangular point 116 at the open dispensing end 62 from the two side walls 109 that just forward from the end of the nozzle mechanism 60. The rounded edges 112 and rounded base 112 facilitate the simultaneous dispensing and application of dry wall tape into corner joints as the operator uses and adjusts the angle of the apparatus.

FIG. 11 shows the front view of the dispensing end 62 of the nozzle mechanism 60. As tape 21 exits the dispensing end 62, it is folded in the center by the triangular base of the corner mechanism 104. The operator adjusts the angle of the nozzle mechanism (assembly) 60 so as to permit the tape to be guided with pressure into a corner joint using the two side walls 109 and the triangular point 116 to affix the tape to an inside corner. By further adjusting the apparatus, the operator also uses the corner mechanism 104 and the folding triangular base thereof to guide dispensed tape around outside corner joints.

FIG. 12 illustrates the mounted corner mechanism 104 using the clip 105 to position the corner mechanism 104 and hold it in place over the serrated, ridge cut bar 80. The triangular point 116 is used as a guide for applying tape 21 from the dispensing end 62 to inside and outside corners.

The present disclosure provides an apparatus for applying a fluid-activated tape onto a wallboard or ceiling joint. Such a joint may be formed by two pieces of drywall or ceiling board and includes a joint on a wall or a corner joint. The apparatus is a drywall tape applicator. The apparatus comprises a housing, a base, a handle, a nozzle assembly, a basin, and a plurality of rollers. A left housing section and a right housing section, when assembled, defines and forms the housing. The housing has a front end and a rear end, and is configured to removably mount a roll of tape at the rear end. The handle is disposed between and coupled with the base and the rear end of the housing. The nozzle assembly is attached to or defined by the front end of the housing. The basin is detachably coupled with the housing and configured to hold a fluid such as water. The plurality of rollers include a first roller disposed inside the basin. The plurality of rollers are configured to feed and transport or dispense a portion of tape from the roll into the fluid of the basin and then out of the nozzle assembly. The tape is coated with adhesive on one side, which can be activated with the fluid such as water.

In some embodiments, the nozzle assembly is rotatable with respect to a longitudinal axis of the housing so that the tape can be applied horizontally or vertically. The nozzle assembly comprises a cutting bar configured to cut a portion of tape transported out of the nozzle assembly. In some embodiments, the left housing section and the right housing section, when assembled, defines the base, the handle, and/or the nozzle assembly including the cutting bar. The left housing section and the right housing section may be made of plastics. In some embodiments, the left housing section and the right housing section defines and provides a roll holder in the housing configured to removably mount a roll of tape. The housing may be open from its top in some embodiments.

The plurality of rollers include a second roller and a third roller disposed parallel to each other to provide a nip at one end of the nozzle assembly and configured to transport the portion of tape out of the nozzle assembly. The second roller and the third roller may also comprise a plurality of ribs for removing excessive fluid. The plurality of rollers may also include a fourth roller disposed inside the housing and between the first roller and the pair of the second and third rollers.

In some embodiments, the apparatus further comprises at least one guide disposed on the nozzle assembly and configured to guide the tape out in a straight line. The apparatus may further comprise at least one belt tab, for example, two belt tabs, attached to an exterior surface of the housing. The at least one belt tab has a clip sized and configured to removably couple the apparatus onto an operator's belt.

In some embodiments, the apparatus further comprises a corner mechanism removably coupled with the nozzle assembly and is configured to apply a portion of tape onto a corner joint. The corner mechanism includes a triangular base and two sidewalls providing a right angle, and is configured to fold the portion of tape when the portion of tape is dispensed out of the nozzle assembly.

In another aspect, the present disclosure provides an apparatus applying a fluid-activated tape onto a wallboard or ceiling joint. Such an apparatus comprises a housing, a base, a handle, a nozzle assembly, a basin, a plurality of rollers, and a corner mechanism. The housing is defined by a left housing section and a right housing section. The housing has a front end and a rear end. The housing is configured to removably mount a roll of tape at the rear end. The handle is disposed between and coupled with the base and the rear end of the housing. The nozzle assembly is attached to or defined by the front end of the housing, and is rotatable with respect to a longitudinal axis of the housing. The basin is detachably coupled with the housing and is configured to hold a fluid. The plurality of rollers include a first roller disposed inside the basin. The plurality of rollers are configured to feed and transport a portion of tape from the roll into the fluid of the basin and then out of the nozzle assembly. The corner mechanism is removably coupled with the nozzle assembly and is configured to apply the portion of tape onto a corner joint.

In some embodiments, the corner mechanism includes a triangular base and two sidewalls providing a right angle, and is configured to fold the portion of tape when the portion of tape is dispensed out of the nozzle assembly. The nozzle assembly comprises a cutting bar having a serrated and ridged structure in some embodiments. In some embodiments, the corner mechanism comprises an elongated clip structure having an upside-down U-shape cross-section removably coupled onto the cutting bar.

In some embodiments, the apparatus is mainly assembled from two pieces including the left housing section and the right housing section, which define the nozzle assembly, the base, and the handle after assembled with screws. In some embodiments, the plurality of rollers include four or less roller in total. The plurality of rollers include a pair of a second roller and a third roller disposed parallel to each other to provide a nip at one end of the nozzle assembly, and a fourth roller disposed inside the housing and between the first roller and the pair of the second and third rollers.

In some embodiments, the present disclosure provides a lightweight, easy to use, hand-held apparatus or applicator and a method for applying drywall tape to wallboard and ceiling joints when finishing walls during construction. The applicator comprises a left housing section and a right housing section including a base, a handle with grips, and a left nozzle and a right nozzle mechanism, a cutting bar and four rollers of the same size. The tool is used with water-based or water-actuated adhesive-backed paper drywall tape to be applied to wall and ceiling joints. The applicator allows easy application of drywall tape in select lengths to the desired wallboard, ceiling or corner joint. The nozzle mechanism rotates and allows the operator to hold the tool in his right or left hand to apply tape from left to right or from right to left and to apply the tape either vertically or horizontally. The nozzle mechanism has a guide piece that facilitates application of the tape in a straight line. A roll is attached to the top of the apparatus in roll holders inside the interior of both the left and right housing. The feeding edge of the tape is fed through guides to rollers and around a roll holding feature into a removable basin of water where contact with water actuates the adhesive on the underside of the tape. The tape then passes through another roller and is pulled through a pair of adjacent rollers that form a nip in the nozzle end of the apparatus. The operator presses the nozzle end of the tool against the wall surface to easily apply tape into the wall or ceiling joint with one easy swing of the arm. The tool permits the operator to easily twist his or her arm to sever the tape in select lengths using a serrated cutting bar affixed to the top of the nozzle mechanism.

The applicator tool can be enlarged in size to apply longer rolls of tape, or made smaller to apply narrower-width drywall tape. Although the present invention has been described in detail and with particularity, it will be appreciated by those skilled in the art that changes and modifications can be made therein without departing from the scope and spirit of the invention. 

What is claimed is:
 1. An apparatus for applying a fluid-activated tape onto a wallboard or ceiling joint, comprising: a housing defined by a left housing section and a right housing section, the housing having a front end and a rear end, the housing configured to removably mount a roll of tape at the rear end; a base; a handle disposed between and coupled with the base and the rear end of the housing; a nozzle assembly attached to or defined by the front end of the housing; a basin detachably coupled with the housing and configured to hold a fluid; and a plurality of rollers including a first roller disposed inside the basin, the plurality of rollers configured to feed and transport a portion of tape from the roll into the fluid of the basin and then out of the nozzle assembly.
 2. The apparatus of claim 1, wherein the nozzle assembly is rotatable with respect to a longitudinal axis of the housing.
 3. The apparatus of claim 1, wherein the nozzle assembly comprises a cutting bar configured to cut a portion of tape transported out of the nozzle assembly.
 4. The apparatus of claim 3, wherein the nozzle assembly including the cutting bar is defined by the left housing section and the right housing section.
 5. The apparatus of claim 1, wherein the base and the handle are defined by the left housing section and the right housing section.
 6. The apparatus of claim 1, wherein the left housing section and the right housing section are made of plastics.
 7. The apparatus of claim 1, wherein the left housing section and the right housing section defines and provides a roll holder in the housing configured to removably mount a roll of tape.
 8. The apparatus of claim 1, wherein the plurality of rollers include a second roller and a third roller disposed parallel to each other to provide a nip at one end of the nozzle assembly and configured to transport the portion of tape out of the nozzle assembly.
 9. The apparatus of claim 8, wherein the second roller and the third roller comprises a plurality of ribs.
 10. The apparatus of claim 8, wherein the plurality of rollers include a fourth roller disposed inside the housing and between the first roller and the second or third roller.
 11. The apparatus of claim 1, further comprising at least one guide disposed on the nozzle assembly and configured to guide the portion of tape in a straight line.
 12. The apparatus of claim 1, further comprising at least one belt tab attached to an exterior surface of the housing, the at least one belt tab having a clip sized and configured to removably couple the apparatus onto an operator's belt.
 13. The apparatus of claim 1, further comprising a corner mechanism removably coupled with the nozzle assembly and configured to apply a portion of tape onto a corner joint.
 14. The apparatus of claim 13, wherein the corner mechanism includes a triangular base and two sidewalls providing a right angle, and is configured to fold the portion of tape when the portion of tape is dispensed out of the nozzle assembly.
 15. An apparatus for applying a fluid-activated tape onto a wallboard or ceiling joint, comprising: a housing defined by a left housing section and a right housing section, the housing having a front end and a rear end, the housing configured to removably mount a roll of tape at the rear end; a base; a handle disposed between and coupled with the base and the rear end of the housing; a nozzle assembly attached to or defined by the front end of the housing, the nozzle assembly being rotatable with respect to a longitudinal axis of the housing; a basin detachably coupled with the housing and configured to hold a fluid; a plurality of rollers including a first roller disposed inside the basin, the plurality of rollers configured to feed and transport a portion of tape from the roll into the fluid of the basin and then out of the nozzle assembly; and a corner mechanism removably coupled with the nozzle assembly and configured to apply the portion of tape onto a corner joint.
 16. The apparatus of claim 15, wherein the corner mechanism includes a triangular base and two sidewalls providing a right angle, and is configured to fold the portion of tape when the portion of tape is dispensed out of the nozzle assembly.
 17. The apparatus of claim 15, wherein the nozzle assembly comprises a cutting bar having a serrated and ridged structure.
 18. The apparatus of claim 16, wherein the corner mechanism comprises a clip structure having an upside-down U-shape cross-section removably coupled onto the cutting bar.
 19. The apparatus of claim 15, wherein the left housing section and the right housing section define the nozzle assembly, the base, and the handle after assembled with screws.
 20. The apparatus of claim 1, wherein the plurality of rollers include a pair of a second roller and a third roller disposed parallel to each other to provide a nip at one end of the nozzle assembly, and a fourth roller disposed inside the housing and between the first roller and the pair of the second and third rollers. 